Swab manufacturing apparatus



Nov. 3, 1964 E. M. NAGLE 3,

SWAB MANUFACTURING APPARATUS Filed March 28, 1960 4 Sheets-Sheet 1 COTTONAPPLYINfi STATIONS GLUE a 9 COTTON SEVERING STATION y u \2 4 M STATION STlCK LOADlNG a,

STATION J STATIONS Tip FORMlNfi STATIONS ZNVENTOR. EDWARD M. NAfiLE WITNESSES BY Nov. 3, 1964 E. M. NAGLE 3,154,818

SWAB MANUFACTURING APPARATUS Filed March 28, 1960 4 Sheets-Sheet 2 i 156 164 l i ,52 I 166' I 1 ,1 J A J INVENTOR. EDW RD .NAGLE ITNESSES A M Nov. 3, 1964 E. M. NAGLE 3,154,813

SWAB MANUFACTURING APPARATUS Filed March 28, 1960 4 Sheets-Sheet 3 INVENTOR. EDWARD M.NA6LE WITNESSES BY QM A QM g zuszg, m. M

Nov. 3, 1964 E. M. NAGLE SWAB MANUFACTURING APPARATUS 4 Sheets-Sheet 4 Filed March 28, 1960 WITNESSES 69M i gm United States Patent 3,154,818 SWAB MANUFACTURING AkPARATUS Edward M. Nagle, New York, N.Y., assignor, by direct and mesne assignments, to Equitable Capital Corporalion, New York, N.Y., a corporation of New York Filed Mar. 28, 1960, Ser. No. 17,898 16 Claims. (Cl. 19145.3)

The present invention relates to the manufacture of cotton-tipped swabs, and more particularly, to improved apparatus for manufacturing such swabs.

Cotton-tipped swabs are well known as medical applicators for applying medicaments to portions of the body or as cleaning devices for removing tenacious discharges from the mucous membranes of the body. Such cotton-tipped swabs and apparatus for manufacturing the same are disclosed in U.S. Patent No. 1,210,720 issued January 2, 1917 to E. W. Stephan; US. Patent No. 1,438,623 issued December 12, 1922 to G. T. Trundle, in; US. Patent No. 1,721,815 issued July 23, 1929 to L. Gerstenzang; US. Patent No. 1,921,604 issued August 8, 1933 to E. C. Bunnell et al.; US. Patent No. 2,228,599 issued January 14, 1941 to S. V. Glickston; US. Patent No. 2,253,852 issued August 26, 1941 to S. W. Glickston; US. Patent No. 2,43 0,648 issued November 11, 1947 to B. Schonrock; U.S. Patent No. 2,557,024 issued June 12, 1951 to H. L. Barber et al.; US. Patent No. 2,576,068 issued November 20, 1951 to W. Ganz; US. Patent No. 2,618,027 issued November 18, 1952 to H. L. Barber et al.; US. Patent No. 2,754,549 issued July 17, 1956 to F. D. Torrent; and US. Patent No. 2,876,501 issued March 10, 1959 to S. W. Glickston.

These conventional swab manufacturing apparatus of the prior art are massive and complicated in structure with an attendant initial cost of over $12,000. Because of the many moving parts breakdowns occassionally occur with resultant lost production and considerable maintenance is required to provide adjustment of such apparatus in order to keep them in operating condition. Additionally in the event of a breakdown it is necessary to partially dismantle the apparatus to repair the trouble. Further such conventional apparatus are limited to production rates of about 115 swabs per minute. Many of these conventional apparatus are not operable to provide swabs of varying length.

it is the general object of the present invention to avoid and overcome the foregoing and other difficulties of and objections to prior art swab manufacturing apparatus by the provision of an improved swab manufacturing apparatus which is operable to produce cotton-tipped swabs at a rate which is about five times the production rate of such conventional apparatus.

Another object of the present invention is the provision of an improved swab manufacturing apparatus which is operable efiiciently to produce cotton-tipped swabs of various lengths.

A further object of the present invention is the provision of an improved swab manufacturing apparatus having an initial cost which is about one-twelfth of the initial cost of conventional apparatus.

Yet another object of the present invention is the provision of an improved swab manufacturing apparatus which is compact and light in weight but rugged and simple in structure.

A still further object of the present invention is the provision of an improved swab manufacturing apparatus having few moving parts, which moving parts are however readily accessible for maintenance and adjustment without requiring the dismantling of such apparatus.

Yet another object of the present invention is the provision of an improved swab manufacturing apparatus which 'ice will operate efiiciently for long periods of time without Xpensive maintenance and adjustment.

The aforesaid objects of the present invention, and other objects which will become apparent as the description proceeds, are achieved by providing an improved swab manufacturing apparatus having a conveyor for supporting a stick and for moving the stick through a path of movement having a plurality of work stations disposed therealong, adhesive applying means at one work station for applying an adhesive to one end of the stick, applying means at other work stations for introducing a web of a fibrous substance into the path of movement of the adhesive carrying end of the stick and in spaced relation thereto with a portion of the web extending beyond the adhesive carrying end, said applying means then being operable to cause the adhesive carrying end to engage and to secure the web thereto thereby permitting the stick to carry the web along the path of movement, said applying means being thereafter operable to fold the extending portion of the web over the adhesive carrying end thereby substantially covering the adhesive carrying end in the folded web, severing means adjacent yet another work station for raising the folded web away from the conveyor and for severing the folded web to provide tufts of the fibrous substance projecting from each side of the covered end, stick rotating means disposed in operative relation to the conveyor and the stick and the tufts carried thereby, and tip forming means at further wor stations for receiving the covered end and for positioning the stick in engagement with the stick rotating means so that the stick is rotated as the covered end thereof is carried by the conveyor through the tip forming means, said tip forming means being operable to thereafter form the covered end into a tip of the predetermined shape.

For a better understanding of the present invention reference should be had to the accompanying drawings, wherein like numerals of reference indicate similar parts throughout the several views and wherein:

FIG. 1 is a side-elevation-al view of the improved swab manufacturing apparatus of the present invention and illustrating diagrammatically the operation of such apparatus;

FIG. 1A is a front-elevational View of the apparatus shown in P16. 1 and is taken from the right side of FF 1, with the cotton applying devices shown in section and portions of the cotton severing devices and tip forming devicm removed for the sake of clarity;

FIG. 2 is a side-elevational view (similar to FIG. 1) of the stick loading device and a fragmentary portion of one of the conveyor wheels adjacent Station 1, the stick loading station;

FIG. 3 is a side-elevational view (similar to FIG. 1) of one of the glue applying devices and a fragmentary portion of one of the conveyor wheels adjacent Station 3, the glue applying station;

FIG. 4 is a fragmentary plan view of the conveyor wheels, friction wheel and the cotton applying devices adjacent Stations 6 through 11, the cotton applying stations, and having the frame members omitted for reasons of simplicity arid clarity and with one of the cotton applying devices shown in horizontal section;

FIG. 5 is a side-elevational viewing along line V-V of PEG. 4 in the direction of the arrows and omitting for the sake of clarity the stick aligning means adjacent Stations 5 and 12 as Well as the sticks and web of cotton adjacent Stations 6 through 11;

FIG. 6 is a side-elevational view (similar to FIG. 1) with one of the frame members cut away to show portions of one of the cotton severing devices and a fragmentary portion of one of the conveyor wheels adjacent Station 15, the cotton severing station and with the gear box on such frame member omitted;

such tip forming device broken away adjacent Stations 31 and 32 to show the friction wheel and the sockets V disposed inside said tip forming devices;

FIG. 9 is a vertical-sectional view along the line lX-IX of FIG. 8 in the direction of the arrows and showing the enlarged cross section of the tip forming device at the start of the tip forming operation at Station 18; and

1G. 10 is an elevational view along the line X-X of PEG. 8 in the direction of the arrows and showing the reduced cross section of the tip forming device at the end of the tip forming operation at Station 41.

With specific reference to the form of the present invention illustrated in the drawings, and referring particularly to F168. 1 and 1A, a pair of frame members for the improved swab manufacturing apparatus of the present invention are indicated generally by the reference numeral 52 and are mounted on a bed plate 54 (FIG. 1A)

so that at least one of' the frame members 52 is movable longitudinally with respect to the other frame member 52 To provide rotatable mounting means for a pair of spaced conveyor wheels 56 (FEGS. 1A and 4), a hollow shaft 53 (FIGS. 1A, 4, 6 and 8) is journalled in each frame member 52 and a conveyor wheel 56 is alfixed to such hollow shaft 56 (FIG. 1A) by means of a set screw 65 Between the conveyor wheels 56 a friction wheel 62 (FIGS. 1A, 4 and 8) is mounted by means of another set screw 66 (FIG. 1A) on a shaft 64 (FIGS. 1, 1A, 4, 6 and 8) which is rotatable within the hollow shafts 58. As shown in FIGS. 1A and 4 such conveyor wheels 56 are mounted on the hollow shafts 53 in spaced relation to each other by means of the screws 66 and are movable longitudinally with respect to the friction wheel 62 on the hollow shafts 58 to vary the spacing between such conveyor wheels 56.

This shaft 64 is connected to the prime mover of the swab manufacturing apparatus and to the hollow shafts 53 as will now be explained.

Drive Means As shown in FIG. 1, the shaft 64 projects from a gear box 66 on the frame member 52 and carries a double sprocket 66 which is connected by a chain 76 to a prime mover, such asa motor (not shown). The shaft 64 and the friction wheel 62 carried thereby are rotated by such motor (not shown) in clockwise direction, as viewed in FIG. 1. In order to rotate the left-hand conveyor wheel 56 (FIG. 1A) in the same direction but at a slower speed of rotation than the friction wheel 62, a gear train (not shown) within the gear box 66 (FIGS. 1 and 1A) connects the shaft 64 to the hollow shaft 53 upon which such left-hand conveyor wheel 56 (FIG. 1A) is mounted. In like manner another gear train (not shown, but contained within another gear box 66, FIG. 1A, mounted on the right-hand frame member 52) connects the shaft 64 to the right-hand hollow shaft 58 thus causing such righthand hollow shaft 58 and the right-hand conveyor wheel 56 carried thereby to rotate at the same speed and in the same direction as the left-hand conveyor wheel 56.

Before proceeding with the description of the operation of the improved swab manufacturing machine of the present invention it is deemed advisable to describe in detail the conveyor wheels 56 (FIGS. 1A, 26 and 8), which constitute the wheel-like conveyor for supporting a stick 96 and for moving said stick 96 through a path of move- 4 ment having plurality of work stations disposed therealong.

Conveyor Wheels Each of the conveyor wheels 56 is provided with a plurality of, for example fifty, spaced peripheral sockets 74 and such conveyor wheels 56 are mounted on the hollow shafts 56 so that corresponding sockets on each of the conveyor wheels 56 are in alignment with each other transverse to the path of movement of said conveyor wheels 56. As shown clearly in FiGS. 2, 3, 6 and 8 the outer edge of the left-hand side wall of each socket 74 terminates in a peripheral are surface 76, While the outer edge of the opposite side wall of each socket 74 ends in a flat tapering surface 73, extending from a peripheral are surface 76 to such opposite side wall.

Having described the conveyor wheels 56, it will be assumed for purposes of illustration that the conveyor wheels 56 are rotating in clockwise direction, as viewed in FIGS. 1, 1A, 3, 4, 6 and 8, and that an empty pair of sockets 74 at Station 50 is approaching Station 1, the stick loading station, adjacent which a stick loading device (FIG. 2) is mounted on the frame members 52, by conventional means (not shown). By rotating the conveyor wheels 56 at about 10 r.p.m., the fifty sockets '74 (multiplied by 10 rpm.) produce about 500 swabs per minute.

Stick Loading Device This stick loading device (for loading a stick 96 into the conveyor) is essentially a box-like structure which is open at the top and at the left-hand side, as viewed in PEG. 2, and such device is desirably fabricated from transparent plastic material to permit observation of the operation of such stick loading device. Such stick loading device has a bottom plate 86, an end plate 82 and a guide plate 84 integrated by means of screws to a pair of side plates 66 (only one of which is shown in FIG. 2). The guide plate 84 and the right-hand portion of the bottom plate 86 define a guideway 88 extending from a tapered feeding passageway 96 to a position adjacent the path of movement of the sockets 74. This tapered feeding passageway 96 is defined by an angled inclined plate 92- (mounted on the bottom plate 66) and an agitating plate 94. As shown in FIG. 2, the guideway 88 is adapted to present a single line of sticks 96 one at a time to the suc cessive pairs of continuously moving sockets 74.

In order to prevent jamming of the sticks 96 in the stick loading device and to insure their fluid movement to a pair of sockets 74, the agitating plate 94 is pivotably mounted on the side plates 86 at 98 and is held in engagement (by the mass of sticks 96) with an agitating cam 119i) eccentrically mounted on a shaft 162 journalled in the side plates 36. This shaft 162 carries a sprocket (not shown) which is driven by a chain 1534 (P18. 1) extending from the double sprocket 68 on the shaft 64.

As the pair of sockets '74 at Station 50 approach Station 1, the stick loading station, the leading associated peripheral arc surfaces 76 hold back the line of sticks 96 in the guideway 88 until the leading stick 96 encounters and rolls down the flat tapering surfaces 78 against the left-hand side walls, as viewed in FIG. 2, of the sockets 74 and then into the sockets 74. When the now loaded sockets 74 at Station 1 pass beyond the guideway 88 the next associated peripheral arc surfaces 76 again hold back the line of sticks 96 in such guideway 88.

The now-loaded sockets 74 are then moved along their path of movement, in a direction indicated by the arrows in F163. 2 and 3, to Station 3 the glue applying station, adjacent which are located adhesive applying means, such as glue applying devices (only one of which is shown in FIG. 3), for applying an adhesive, such as glue, to theends of the stick 96.

Glue Applying Devices 7 Since the two glue applying devices (which are operaible by movement of the ends of the stick 96 adjacent Station 3 to apply glue to such ends) are identical, it is deemed suflicient to describe the glue applying device (FIG. 3) which would be seen if the improved swab manufacturing machine of the present invention is viewed from in front of FIG. 1. As shown in FIG. 4, the ends of the stick 96 project beyond the conveyor wheels 56.

This glue applying device shown in FIG. 3, has a glue reservoir 1% mounted by means of screws (not shown) in a circular hole 138 (FIG. 1) pro'ided in the frame member 52. To provide rotatable mounting means for a glue applying wheel 119, a shaft 112 (which carries such glue applying wheel 119) is mounted in and retained in a semi-circular hole (not shown) in the end walls of the glue reservoir 196 by means of two reduced shank sections of such shaft 112.

As the adjacent end of the stick S6 approaches Station 3, the glue applying station, such end of the stick S6 engages a blade 114 (one of a plurality of such blades 114 projecting radially from the periphery of the glue applying wheel 110), thereby causing such glue applying wheel lit) to rotate. Rotation of this glue applying wheel 11-9 causes the periphery of the latter to become coated with glue as it passes through the glue (not shown) within the glue reservoir 1%, which glue is applied to the contiguous end of the stick 96 when the end of the stick 96 contacts the glue covered peripheral surface of the glue applying wheel 11% at Station 3, the glue applying station (PEG. 3).

it will be understood by those skilled in the art that during the movement of the stick 96 adjacent Station 3 such stick 96 is resting on the friction wheel 62 (FIGS. 1A, 4 and 8), which friction wheel 62 is rotating in the same clockwise direction as the conveyor wheels 56 cut at a higher speed, thereby causing the stick 96 to rotate in the sockets 74 with attendant exposure of all portions of the end of such stick 96 to the glue. A stationary peripheral retaining plate 115 (portions of which are shown in FIGS. 1A and 4) is mounted on the frame members 52, extends from Station 2 through Station 14 and prevents the rotating stick 96 from jumping out of the sockets '74. in addition, stationary alignment means (not shown) may be disposed on the frame member 52 along the path of movement of such stick 96 from Station 1 through Station 4 to centralize the stick 96 with respect to the sockets i4 and to dispose the end of the stick 96 in operative relation with respect to the glue applying wheel 11%.

When the stick $6 arrives adjacent Station 4, stationary alignment plates 116 (FiGS. 3 and 4) on the frame members 52 (not shown in FIG. 4) align such stick 96 preparatory for the cotton applying operation performed at Stations 6 through 11 by applying means for applying a fibrous substance, such as cotton, as exemplified by the cotton applying devices shown in FIGS. 4 and 5. it will be appreciated that the alignment plates 116 are provided with flat projections 117 (FiG. 4) which will elevate the stick 96 in the sockets 74 and eliminate contact of such stick 96 with the friction wheel 62, thus arresting the rotation of the stick 95 which must not rotate during the cotton applying operation at Stations 6 through ll.

Cotton Applying Devices Each cotton applying device has a horn-like body 118 which is mounted in a U-shaped slot 119 (FIG. 1) provided in the periphery of the adjacent frame member 52 and is secured to the frame member 52 by screws (not shown). Each body 118 is provided (FIGS. 4 and with a generally circular cotton feeding aperture 12% adjacent Station 5 and has a longitudinal cotton folding slot 122 (FlG. 1A) cut in the inner face of the body 113. In order to elevate the stick 6 in its sockets '74 (out of contact with the friction wheel 62) the body 113 is provided with an arcuate ledge 1 4 (FIGS. 4 and 5) extending from the body 118 from a point adjacent Station 5 to a point adjacent Station 11.

Referring to the cotton feeding apertures 120, it will be noted that the bottom 126 of each cotton feeding aperture 124i is lower (adjacent Station 6, FIG. 5) than the arcuate ledge 124, thereby permitting a flat roving or web of a fibrous substance, such as the cotton 128, in such cotton feeding aperture 12% to be disposed below the glued end of the stick )6 before such glued end of the stick 96 engages and becomes stuck to the web of cotton 128 at Station 6. Thereafter the moving stick 96 moves the now attached web of cotton 128 through the cotton feeding device therewith. This bottom I126 tapers upwardly in a direction toward Station 7 as indicated in FIG. 5, and at a point indicated by the dotted line 13% (FIG. 4) between Stations 6 and 7 is at the same elevation as the arcuate ledge 12 4.

Referring now to the cotton applying device shown in the upper portion of PEG. 4, it will be appreciated that an inner face 131 of the upper portion of each body 118 (which upper portion is not shown in the lower portion of FIG. 4) projects inwardly beyond the tapered back wall 132 of the cotton folding slot 122 to define an upper face 136 of the cotton folding slot 122. Further this upper face 136 (FIG. 5) of each cotton folding slot 122 tapers arcuately downwardly toward the arcuate ledge 124 (from Station to Station 1 1) so that the cross section of the cotton folding slot 122 at Station 1 1 is smaller than its cross section at Station 7. In addition, due to the tapering back wall 152 or" such cotton folding slot 122 (shown in the lower portion of 4), the depth of each cotton folding slot 122 at Station 11 is less than its-depth at Station 7.

As shown in the lower portion of FIG. 4, when the web of cotton 12% is dragged along by the moving stick in the direction of the arrow (hi6. 4) an outer face 138 of this web of cotton 12S engages the tapered back wall 132 of the cotton folding slot 122 (FIG. 4) at Station 7. This tapered back wall 132 cooperates with the arcuately tapered upper face 136 (FIG. 5) to fold the half portion of the web of cotton 1.28 (which half portion projects beyond the glued end of the stick 96) over such glued end of the stick 96, as shown in the lower portion of FIG. 4. At Station 11 the web of cotton 128 is folded over the glued end of the stick S6 and secured thereto.

From the above description it is apparent that applying means have been provided for introducing a web of fibrous substance into the path of movement of the adhesive carrying end of the stick 96 and in spaced relation thereto with a portion of the web extending beyond the adhesive carrying end. The applying means is then operable to cause the adhesive carrying end to engage and to secure said web thereto thereby permitting said stick 96 to carry Said web along its path of movement. Thereafter the applying means is operable to fold the extending portion of the web over the adhesive carrying end thereby substantially covering the adhesive carrying end in the folded Web.

etween Station 11 and Station 12 (FIG. 4) the stick S6 engages a stationary alignment plate 146) and is maintained thereby in the desired centralized alignment with respect to the conveyor wheels 56. Simultaneously such stick 96 rides onto flat projections or plates 142 which lift such stick 96 in the sockets 74 out of contact with the friction wheel 62 to prevent rotation of such stick 6 and the web or" cotton 128 now secured thereto. The alignment plates 1 .0 and flat projections 142 extend to a point adjacent Station 15, the cotton severing station, but, for reasons of clarity they are not shown in FIG. 6, which FIG. 6 shows a severing means, namely one of the cottom severing devices, at Station 15.

This severing means is operable to raise the folded web away from the conveyor and to sever the folded web thus providing tufts of the fibrous substance projecting from each side of the covered end of the stick 96.

7 7 Cotton Severing Devices Referring now to FIG. 1A it will be appreciated that each cotton severing device has a shaft 144 journalled in the associated frame member 52 to provide rotatable mouting for a movable cutting wheel 146 disposed between the frame member 52 and the adjacent conveyor wheel 56. Each'shaft 144 extends through the adjacent gear box 66 and is connected by gears (not shown) but contained within the gear box as to the shaft 64 and is driven thereby in the same clockwise direction, as viewed in PEG. 6, as the conveyor wheels 56.

In order to provide movable cutting means a plurality of movable cutters 148 (FIG. 6) are mounted in spaced relation on the periphery of the movable cutting wheel 146. Each movable cutter 148 is mounted at an angle to a radial plane through the longitudinal axis of the movable cutting wheel 146 and the center of such movable cutter 143 so that a cutting edge defined by a flat top surface 159 and a flat tapered side surface 152 will be disposed at the same angle.

To provide a cooperating stationary cutting means at Station 15, the cotton severing station, a resiliently mounted stationary cutter 154 (FIGS. 6 and 7) is utilized. As shown in FIG. 7 (which it will be remembered is a front-elevational view of the stationary cutter 154 taken from Station l4), such stationary cutter 154 is disposed in a slot 155 in a mounting plate 156 with a resilient rubber cushioning member 158 between the stationary cutter 154 and the end of the slot 155 in the mounting plate 156. Pins 16% project from the mounting plate 156 through elongated clearance slots 162 in the stationary such stationary cutter 154, thereby preventing damage to the cutting edges of the stationary cutter 154 and the movable cutter 148. This retaining plate (not shown) is positioned by the pins 160 and secured to the mounting plate 156 by screws (not shown) threadable into holes 163 is such mounting plate 156. So that the cutting edge of the stationary cutter 154 will be disposed at an equal but opposite angle with respect to the above mentioned radial plane through the longitudinal 3X18 of the movable cutting wheel 146 and the center of such stationary cutter 154, a side face.1fi4 of the mounting plate 156 is suitably tapered and secured to the adjacent frame member 52 as by screws 166.

When the stick 96 and the web of cotton 123 (secured and folded around the ends of the stick 96) arrive adjacent Station 15, the cotton severing station, a movable cutter 143-at each end of the stick 96 (FIG. 6) moves between adjacent sticks 96 to raise the web of cotton 128 radially outwardly from the sticks 96 and against a stationary retaining shoe (not shown). 7 Thereafter, the raised mid-portion of the Web of cotton 12% is forced by the movable cutter 148 (moving at the same speed as the sticks against the resiliently mounted stationary cutter 154 and severed. g

The stock 96, now carrying two laterally projecting tufts of cotton 12% on each end thereof then moves to Station 17 suitably prepared for the tip forming operation, which operation is performed by tip-forming means or devices 167 (FIGS. 8-10) at Stations 17 through 41. Each tip forming means is utilized for receiving the covered end of the stick 96 and for positioning said stick in engagement with the stick rotating means (i.e., friction wheel 62) so that said stick is rotated as said covered end thereof is carried by said conveyor through said tip forming means. Each tip forming means is operable to thereafter form the covered end into a tip of the desired shape. I

' Tip Forming Devices As shown in FIG. 1A, the tip forming devices 167 are mounted on the adjacent frame members 52 in operative relation to the sockets 74. Between Station 17 and Station 18 (FIG. 8) the ends of the stick $6 encounter guide lips 168 on first die members 176 (only one of which is shown in FlGS. 8, 9 and 10) of the tip forming devices 167 and such stick 9d is forced downwardly thereby in the sockets 74 into engagement'with the friction wheel 62. so that during the tip forming operation such stick 96 is rotated. in addition to the above-mentioned first die member 1743, each tip forming device 167 comprises a second die member 172 which is secured to the first die member 17% (FIGS. 9 and 10) to provide a tip forming cavity 174.

This tip forming cavity 174 is provided with a stick aperture defined by the opposed faces 176 and 178, shown by the solid lines in FIGS. 9 and 10 and by the dotted lines.

in FIG. 8 and a die portion defined by the side walls lii-ll and 182 and end wall 184 (all indicated by solid lines in FIGS. 9 and 10 and by dotted lines in FIG. 8).

As indicated from a consideration of FIGS. '9 and 10, the cross section of each tip forming cavity 174 gradually tapers from the cross section shown in FIG. 9 (at Station l8) to the (final tip shape) cross section at Station 41 shown in FIG. 10. Continuous rotation of the stick 96 during the movement of its cotton tufted ends through the tip forming cavities 174 provides cotton tips 123 at Station 41 of the desired shape. it is obvious to those skilled in the art that by varying the cross-sectional shape of the tip forming cavities 174 any desired shape of cotton tip 128 may be obtained.

During the'tip forming operation a chemical agent is introduced into the tip forming cavities 174 by a fluid supply means (FiG. 8) at Station 2()'to prevent blossoming (i.e. expansion of the finished cotton tips 128 from their final shape), to prevent black spotting and mildewing thereof while in storage, and further to aid in the coup pacting of the cotton 123 during such tip forming operation.

The chemical agent may be a water solution soluble cellulose gum, such as fMethocel, the trade name for such a gum manufactured by the Dow Chemical Com- 7 Fluid Supply Means This fluid supply means has a pair of conduits 186 (only one conduit 136 being shown in FIG. 8), each extending from a fluid supply means (not shown) which contains the chemical agent and through an aperture 183 at Station 20 in each tip forming device 1:57 to introduce such chemical agent into the tip forming cavity 174. To provide means for controlling the flow of chemical agent into each tip forming cavity 174, a suitable valve 194 is disposed in each conduit 186.

In order to provide means for drying the formed cotton tips 128 on the ends of the stick, a portion 167' of each tip forming device 157 adjacent Stations 39-41 is provided with heating means and the heating section is electrically insulated by a suitable insert 1% (at Station 38) from the remaining portion of such tip forming devices Heating Means As shown in FIG. 8, the heating means is of the electrical type and has a conductor 194 extending from one side of a suitable voltage supply (indicated by the legend "A.C. Voltage Supply) through a manually operated normally-open switch 196 to one side of a heating element (not shown) but contained within the portion 167' of each tip forming device. Another conductor 1% connects the other side of the voltage supply through a variable resistor 26%) and through a thermostat element (not shown) but within the portion 167' to the other side of the heating element (not shown).

Closure of the switch 196 causes the portion 167' of each tip forming device 167 to be heated to the desired temperature required to dry the cotton tips 128 on the ends of the stick 96. The thermostat element (not shown) in the usual manner maintains such desired temperature.

When the now finished swab leaves Station 41 such swab is engaged by a discharge means adjacent Station 42, the discharge station.

Discharge Means As shown in FIGS. 8 and 10 the discharge means comprises a stationary cam 282 formed of transparent plastic and mounted (FIG. 10) in the second die member 172 of the portion 167' of each tip forming device 367.

When the still rotating swab nears Station 42 such swab rides up along the stationary cams 202 and is unseated from the sockets 74, falling thereafter into a suitable container (not shown) or onto a suitable conveyor (not shown).

It will be understood by those skilled in the art that the conveyor wheels 56 which comprise the conveyor may be replaced by a wheel-like drum (not shown) provided with a plurality of (for example fifty peripheral slots instead of the registering sockets 74) with a pair of friction wheels 62 mounted on either side of the wheel-like conveyor (not shown) adjacent each frame member 52. Further if the stick 96 is barbed at each end by apparatus of the type disclosed in US. Patent No. 2,492,027 issued December 20, 1949 to H. L. Barber et al., the glue applying devices may be eliminated. In addition the heating means connected to the portions 167' of the tip forming devices 167 may be disconnected and such portions 167 enclosed in a suitable oven mounted on the frame members 52. Also it is apparent that the web of soft white fibrous cotton 128 may be replaced by other fibrous material, such as wool, glass wool, and steel wool to produce industrial, as well as medical, swabs.

It will be recognized by those skilled in the art that the objects of the present invention have been achieved by the provision of an improved swab manufacturing apparatus operable to produce cotton-tipped swabs at a rate which is about five times the production rate of presently known conventional apparatus. In order to permit the improved swab manufacturing apparatus to efiiciently produce cotton-tipped swabs of various lengths, the frame members 52 are mounted on the bed plate 54 to permit longitudinal .movement thereof and the conveyor wheels as are simi larly mounted on their respective shafts 51%. This improved swab manufact ring apparatus has an initial cost which is about one twelfth of the initial cost of conventional apparatus. Further, the improved swab manufacturing apparatus is compact (i.e. the conveyor wheels 56 having a diameter of about 10"). The apparatus is light in weight (weighing about 80 lbs.) but is desirably rugged and simple in structure. Additionally, the improved swab manufacturing apparatus has few moving parts, which moving parts are readily accessible for maintenance and adjustment without requiring the dismantling of the apparatus. Further, the improved swab manufacturing apparatus will operate efliciently for long periods of time without expensive maintenance and adjustment.

While in accordance with the patent statutes a preferred embodiment of the present invention has been illustrated and described in detail, it is to be particularly understood that the invention is not limited thereto or thereby.

I claim: l 1. Apparatus for manufacturing a swab comprising a "stick provided with a tip having a predetermined shape rality of work stations disposed therealong, adhesive applying means at one work station for applying an adhesive to one end of said stick, applying means at other work stations for guiding a web of said fibrous substance into the path of movement of the adhesive carrying end of said stick and in spaced relation thereto with a portion of said web extending beyond said adhesive carrying end, said applying means then causing said adhesive carrying end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said applying means then causing the extending portion of said web to fold over said adhesive carrying end thereby substantially covering said adhesive carrying end in the folded web, severing means adjacent yet another work station for raising said folded web away from said conveyor and for severing said folded web to provide tufts of said fibrous substance projecting from each side of the covered end, stick rotating means disposed in operative relation to said conveyor and the stick and the tufts carried thereby, and tip forming means at further work stations for receiving said covered end and for positioning said stick in engagement with said stick rotating means so that said stick is rotated as said covered end thereof is carried by said conveyor through said tip forming means, said tip forming means thereafter forming said covered end into a tip of the predetermined shape.

2. Apparatus for manufacturing a swab comprising a stick provided with a barbed end and with a tip having a predetermined shape, said tip being formed of a fibrous substance, said apparatus comprising a conveyor for supporting said stick and for moving said stick through a path of movement having a plurality of work stations disposed therealong, applying means at one group of work stations for guiding a web of said fibrous substance into the path of movement of the barbed end of said stick and in spaced relation thereto with a portion of said web eX- tending beyond said barbed end, said applying means then causing said barbed end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said applying means then causing the extending portion of said web to fold over said barbed end thereby substantially covering said barbed end in the folded web, severing means adjacent yet another work station for raising said folded web away from said conveyor and for severing said folded web to provide tufts of said fibrous substance projecting from each side of the covered end, stick rotating means disposed in operative relation to said conveyor and the stick and the tufts carried thereby, and tip forming means at further work stations for receiving said covered end and for positioning said stick in engagement with said stick rotating means so that said stick is rotated as said covered end thereof is carried by said conveyor through said tip forming means, said tip forming means thereafter forming said covered end into a tip of the predetermined shape.

3. Apparatus for manufacturing a swab comprising a stick provided with a tip having a predetermined shape and formed of a fibrous substance, said apparatus comprising a conveyor for supporting said stick and for moving said stick through a path of movement having a plurality of work stations disposed therealong, stick loading means at one work station for loading said stick into said conveyor, adhesive applying means at another work station for applying an adhesive to one end of said stick, applying means at other work stations for guiding a web of said fibrous substance into the path of movement of the adhesive carrying end of said stick and in spaced relation thereto with a portion of said web extending beyond said adhesive carrying end, said applying means then causing said adhesive carrying end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said applying means then causing the extending portion of said web to fold over said adhesive carrying end thereby substantially covering said adhesive carrying end with the folded 'web, severing means adjacent yet another work station for raising said folded web away from said conveyor and for severing said folded web to provide tufts of said fibrous substance projecting from each side of the covered end, stick rotating means disposed in operative relation to said conveyor and the stick and the tufts carried thereby, and tip forming means at further work stations for receiving said covered end and for positioning said stick in engagement with said stick rotating means so that said stick is rotated as said covered end thereof is carried by said conveyor through said tip forming means, said tip forming means thereafter forming said covered end into a tip of the predetermined shape.

4. Apparatus for manufacturing a swab comprising a stick provided with a tip having a predetermined shape and formed of a fibrous substance, said apparatus comprising a conveyor for supporting said stick and for moving said stick through a path of movement having a plurality of work stations disposed therealong, adhesive applying means at one work station for applying an adhesive to one end of said stick, applying means at other work stations for guiding a web of said fibrous substance into the path of movement of the adhesive carrying end of said stick and in spaced relation thereto with a portion of said web extending beyond said adhesive carrying end, said applying means then causing said adhesive carrying end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said applying means then causing the extending portion of said web to fold over said adhesive carrying end thereby substantially covering said adhesive carrying end with the folded web, severing means adjacent yet another work station for raising said folded web away from said conveyor and for severing said folded Web to provide tufts of said fibrous material projecting from each side of the covered end, stick rotating means disposed in operative relation to said conveyor and the stick and the tufts carried thereby, tip forming means at further work stations for receiving said covered end and for positioning said stick in engagement with said stick rotating means so that said stick is rotated as said covered end thereof is carried by said conveyor through said tip forming means, said tip forming means thereafter forming said covered end into a tip of the predetermined shape, andfiuid applying means connected to said tip forming means for applying a fluid to said covered end thereby facilitating the compacting of said covered end into said tip by said tip forming means, and preventing blossoming, black spotting and mildewing of said tip while said swab is in storage.

5. Apparatus for manufacturing a swab comprising a stick provided with a tip having a predetermined shape and formed'of a fibrous substance, said apparatus comprising a conveyor for supporting said stick and for moving said stick through a path of movement having a plurality of work stations disposed therealong, adhesive applying means at one work station for applying an adhesive to one end of said stick, applying means at other work stations for guiding a web of said fibrous substance into the path of movement of the adhesive carrying end of said stick and in spaced relation thereto with a portion of said web extending beyond said adhesive carrying end, said applying means causing said adhesive carrying end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said applying means then causing the extending portion of said web to fold over said adhesive carrying end thereby substantially covering said adhesive carrying end with the folded web, severing means adjacent yet another work station for raising said folded web away from said conveyor and for severing said folded web to provide tufts of said fibrous substance projecting from each side of the covered end, stick rotating means disposed in operative relation to said conveyor and the stick and the tufts carried thereby, tip forming means at further work stations for receiving said covered end andfor positioning said stick in engagement with said stick rotating means so that said stick is rotated as said covered end thereof is carried by said conveyor through said tip forming means, said tip forming means thereafter forming said covered end into a tip of the predetermined shape, and heating means operatively associated with said tip forming means for drying the formed tip.

6. Apparatus for manufacturing a swab comprising a stick provided with a tip having a predetermined shape and formed of a fibrous substance, said apparatus comprising a conveyor for supporting a stick and for moving said stick through a path of movement having a plurality of work stations disposed therealong, stick loading means at one work station for loading said stick into said conveyor, adhesive applying means at another Work station for applying an adhesive to one end of said stick, applying means at other work stations for guiding a web of said fibrous substance into the path of movement of the adhesive carrying end of said stick and in spaced relation thereto with a portion of said web extending beyond said adhesive carrying end, said applying means then causing said adhesive carrying end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said applying means then causing the extending portion of said web to fold over said adhesive carrying end thereby substantially covering said adhesive carrying end with the folded web, severing means adjacent yet another work station for raising said folded web away from said conveyor and for severing said folded web to provide tufts of said fibrous substance projecting from each side of the covered end, stick rotating means disposed in operative relation to said conveyor and the stick and the tufts carried thereby, tip forming means at further work stations for receiving said covered end and for positioning said stick in engagement with said stick rotating means so that said stick is rotated as said covered end thereofis carried by said conveyor through said tip forming means, said tip forming means thereafter forming said covered end into a tip of the predetermined shape, and fluid applying means connected to said tip forming means for applying a fluid to said covered end thereby facilitating the compacting of said covered end into said tip by said tip forming means and preventing lossoming, black spotting and mildewing of said tip while said swab is in storage.

7. Apparatus for manufacturing a swab comprising a stick provided with a tip having a predetermined shape and formed of cotton, said apparatus comprising a conveyor for supporting said stick and for moving said stick through a path of movement having a plurality of work stations disposed therealong, stick loading means at one work station for loading said stick into said conveyor, glue applying means at another work station for applying glue to one end of said stick, cotton applying means at other work stations for guiding a web of cotton into the path of movement of the glued end of said stick and in spaced relation thereto with a portion of said web extending beyond said glued end, said cotton applying means then causing said glued end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said cotton applying means then causing the extending portion of said web to fold over said glued end thereby substantially covering said glued end with the folded web, cotton severing means adjacent yet another work station for raising said folded web away from said conveyor and for severing said folded Web to provide tufts of cotton projecting from each side of the cotton covered end, stick rotating means disposed in operative relation 'to said conveyor and the stick and the tufts carried thereby, tip forming means at further work stations for receiving said cotton covered end and for positioning said stick in engagement with said stick rotating means so that said stick is rotated as said cotton covered end thereof is carried by said conveyor through said tip forming means, said tip forming means thereafter forming said cotton covered end into a tip of the predetermined shape, fluid applying means connected to said tip forming means for applying a fluid to said cotton covered end thereby facilitating the compacting of said cotton covered end into said tip by said tip forming means and preventing blossoming, black spotting and mildewing of said tip while said swab is in storage, and heating means operatively associated with said tip forming means for drying the formed tip.

8. Apparatus for manufacturing a swab comprising a stick provided with a tip having a predetermined shape and formed of cotton, said apparatus comprising a conveyor for supporting said stick and for moving said stick through a path of movement having a plurality of work stations disposed therealong, stick loading means at one work station for loading said stick into said conveyor, glue applying means at another work station for applying glue to one end of said stick, cotton applying means at other work stations for guiding a web of cotton into the path of movement of the glued end of said stick and in spaced relation thereto with a portion of said web extending beyond said glued end, said cotton applying means then causing said glued end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said cotton applying means then causing the extending portion of said web to fold over said glued end thereby substantially covering said glued end with the folded web, cotton severing means adjacent yet another work station for raising said folded web away from said conveyor and for severing said folded Web to provide tufts of cotton projecting from each side of the cotton covered end, stick rotating means disposed in operative relation to said conveyor and the stick and the tufts carried thereby, tip forming means at further work stations for receiving said cotton covered end and for positioning said stick in engagement with said stick rotating means so that said stick is rotated as said cotton covered end thereof is carried by said conveyor through said tip forming means, said tip forming means thereafter forming said cotton covered end into a tip of the predetermined shape, fluid applying means connected to said tip forming means for applying a fiuid to said cotton covered end thereby facilitating the compacting of said cotton covered end into said tip by said tip forming means and preventing blossoming, black spotting and mildewing of said tip while said swab is in storage, heating means cooperatively associated with said tip forming means for drying the formed tip, and discharge means disposed at still another Work station for causing the ejection of said swab from said conveyor.

9. For a swab manufacturing apparatus having a conveyor for supporting an arrested stick carrying an adhesive on one end and for moving said stick through a path of movement with a plurality of work stations disposed therealong, applying means including guide means with a first portion at one group of work stations for guiding a web of a fibrous substance into the path of movement of the adhesive carrying end of said stick and in spaced relation thereto with a portion of said web extending beyond said adhesive carrying end, said guide means then causing said adhesive carrying end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, and said guide means including a second portion at a second group of work stations for causing the extending portion of said web to fold over said adhesive carrying end thereby substantially covering said adhesive carrying end with the folded web, and swab-forming means at a subsequent group of work stations and including stickrotating means for rotatably forming the swab after the fibrous web has been folded over the adhesive carrying end of the stick.

10. For a swab manufacturing apparatus having a conveyor for supporting a stick capacitated at one end to retain a fibrous substance, said conveyor moving said stick through a path of movement with a plurality of Work stations disposed therealong, applying means at one group of work stations provided with a feeding aperture for guiding a web of a fibrous substance into the path of movement of said one end of said stick and in spaced relation thereto with a portion of said web extending beyond said one end, said feeding aperture then causing said one end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said applying means also being provided with a folding aperture in communication with said feeding aperture for folding the extending portion of said web over said one end thereby substantially covering said one end with the folded web.

11. For a swab manufacturing apparatus having a conveyor for supporting a stick carrying glue on one end and for moving said stick through a path of movement with a plurality of work stations disposed therealong, cotton applying means at one group of work stations provided with a feeding aperture for guiding a Web of cotton into the path of movement of the glued end of said stick and in spaced relation thereto with a portion of said web extending beyond said glued end, said feeding aperture then causing said glued end to engage and to secure said web thereto thereby permitting said stick to carry said web along said path of movement, said cotton applying means also being provided with a folding aperture in communication with said feeding aperture, said folding aperture converging vertically and laterally toward said glued end along said path of movement for folding the extending portion of said web over said glued end thereby substantially covering said glued end with the folded web.

12. For a swab manufacturing apparatus having a conveyor for supporting a plurality of spaced sticks carrying a web of a fibrous substance secured to one end of said sticks and for moving said sticks and the web carried thereby through a path of movement with a plurality of work stations disposed therealong, severing means having a movable cutter adjacent one work station for rais ing said Web between adjacent sticks away from said conveyor, and a stationary cutter at said one work station and engageable by said movable cutter with said web therebetween to sever said web thus providing tufts of said fibrous substance projecting from each side of the end of each stick, one of said cutters being resiliently mounted to prevent damage to the cutting edges of said cutters.

13. For a swab manufacturing apparatus having a conveyor for supporting a plurality of spaced sticks carrying a web of cotton secured to one end of said sticks and for moving said sticks and the Web carried thereby through a path of movement with a plurality of work stations disposed therealong, severing means having a movable cutter adjacent one work station for raising said web between adjacent sticks away from said conveyor, and a stationary cutter resiliently mounted at said one work station and engageable by said movable cutter with said Web therebetween to sever said web thus providing tufts of cotton projecting from each side of the end of each stick, the resilient mounting of said stationary cutter being operable to prevent damage to the cutting edges of said cutters.

14. For a swab manufacturing apparatus having a conveyor for supporting a succession of spaced arrested sticks connected by a continuous web of a fibrous substance secured to corresponding ends of said sticks and for moving said sticks and the fibrous substance carried thereby through a path of movement with a plurality of work stations disposed therealong, severing means successively operative between said sticks to break the web into separated tufts of fibrous substance while being continuously advanced by said conveyor, stick rotating means having friction means disposed in operative relation to said con- 15 veyor and the sticks carried thereby, and tip forming means at one group of work stations for receiving the tuft carrying end and including elongated guide means engaging successive sticks for forcing said sticks into engagement with said stick rotating means so thatsaid sticks 1 are rotated uniformly as said tuft carrying end thereof is carried by said conveyor through said tip forming means,

saidtip forming means thereafter forming said tuft carrying'end into a tip of a predetermined shape.

15. Fora swab manufacturing apparatus having a conveyor for supporting a'succession of spaced arrested sticks connected by a continuous web of a fibrous substance secured to corresponding ends of said sticks and for moving said sticks and the fibrous substance carried thereby through a path of movement with a plurality of Work stations disposed therealong, severing means successively operative between said sticks to break the web into separated tufts of fibrous substance while being continuously advanced by said conveyor, stick rotating means having friction means disposed in operative relation to said conveyor and the stick carried thereby, tip forming means at one groupof Work stations for receiving the tuft carrying end and includingielongated guide means engaging successive sticks for forcing each stick into engagement with said stick rotating means so that said stick 'isrrotated uniformly as said tuft carrying end thereof is carried by said conveyor'through said tip forming means, said tip forming means thereafter'forming said tuft carrying end into a'tip of a'predeterrnined shape, and fluid applying means connected to said tip forming means for applying a fluid to said tuft carrying end thereby facilitating :the compacting-of said tuft carrying endinto said tip by said tip forming means and preventing blossoming, black spotting and mildewing of said tip while said swab is in storage.

16. For a swab manufacturing apparatus having a con- 16 veyorfor supporting a successionof spaced arrested sticks connected by'a continuous web of a fibrous substance se cured to corresponding ends of said sticks and for moving said sticks and the fibrous substance carried thereby through a path of movement with a plurality of Work stations disposed therealong, severing means successively operative between said sticks to break the web into separated tufts of fibrous substance while being continuously advanced by said conveyor, stick rotating means having friction means disposed in operative relation to said conveyor and the stick carried thereby, tip forming means at one group of work stations for receiving the tuft carrying end and including elongated guide means engaging successive sticks for forcing each stick into engagement with said stick rotating means so that said stick is rotated uniformly as said tuft carrying end thereof is carried by said conveyor through said tip forming means,

said tip forming means thereafter forming said tuft carry- References Cited in the file of this patent UNITED STATES PATENTS 2,228,599 Glickston Jan. 14, 1941 2,253,852 Glickston Aug. 26, 1941 2,430,648 Schonrock Nov. 11, 1947 2,557,024 Barber et a1 June 12, 1951 2,576,068 Ganz Nov. 20, 1951 2,754,549 Torrent July 17, 1956 new 

9. FOR A SWAB MANUFACTURING APPARATUS HAVING A CONVEYOR FOR SUPPORTING AN ARRESTED STICK CARRYING AN ADHESIVE ON ONE END AND FOR MOVING SAID STICK THROUGH A PATH OF MOVEMENT WITH A PLURALITY OF WORK STATIONS DISPOSED THEREALONG, APPLYING MEANS INCLUDING GUIDE MEANS WITH A FIRST PORTION AT ONE GROUP OF WORK STATIONS FOR GUIDING A WEB OF A FIBROUS SUBSTANCE INTO THE PATH OF MOVEMENT OF THE ADHESIVE CARRYING END OF SAID STICK AND IN SPACED RELATION THERETO WITH A PORTION OF SAID WEB EXTENDING BEYOND SAID ADHESIVE CARRYING END, SAID GUIDE MEANS THEN CAUSING SAID ADHESIVE CARRYING END TO ENGAGE AND TO SECURE SAID WEB THERETO THEREBY PERMITTING SAID STICK TO CARRY SAID WEB ALONG SAID PATH OF MOVEMENT AND SAID GUIDE MEANS INCLUDING A SECOND PORTION AT A SECOND GROUP OF WORK STATIONS FOR CAUSING THE EXTENDING PORTION OF SAID WEB TO FOLD OVER SAID ADHESIVE CARRYING END THEREBY SUBSTANTIALLY COVERING SAID ADHESIVE CARRYING END WITH THE FOLDED WEB, AND SWAB-FORMING MEANS THAT AT SUBSEQUENT GROUP OF WORK STATIONS AND INCLUDING STICKROTATING MEANS FOR ROTATABLY FORMING THE SWAB AFTER THE FIBROUS WEB HAS BEEN FOLDED OVER THE ADHESIVE CARRYING END OF THE STICK. 